GV 2500A GV 3800A GV 5600A GV 6600A
0171887en
0609
Generator
GV 2500A
GV 3800A
GV 5600A
GV 6600A
REPAIR MANUAL
0
1
7
1
8
8
7
E
N
002
GV Generator Repair
Foreword
Machines
covered by
this manual
Machine
documentation
„
„
„
„
„
Expectations
for
information in
this manual
„
„
„
Copyright
notice
„
„
„
„
Machine
Item Number
GV 2500A
0620286, 0620542
GV 3800A
0620287, 0620409, 0620334
GV 5600A
0620288, 0620410, 0620335
GV 6600A
0620289, 0620336
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
This manual provides information and procedures to safely operate and maintain the above Wacker Neuson model(s). For your own safety and to reduce the
risk of injury, carefully read, understand, and observe all instructions described
in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2009 by Wacker Neuson Corporation.
This publication may be reproduced through photocopying by the original
purchaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be
prosecuted.
CALIFORNIA
Proposition
65 Warning:
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified
wc_tx000771gb.fm
3
GV Generator Repair
and rated by the United States Forest Service for this purpose. In order to comply
with local laws regarding spark arresters, consult the engine distributor or the local
Health and Safety Administrator.
NOTICE:
Trademarks
wc_tx000771gb.fm
All trademarks referenced in this manual are the property of their respective owners.
4
GV Generators
1
Foreword
3
Safety Information
7
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
Callouts Found in this Manual .............................................................. 7
Safety Guidelines for Operating the Machine ....................................... 8
Safety Guidelines while Using Internal Combustion Engines ............... 9
Safety Guidelines for Maintaining the Machine .................................. 10
Label Locations .................................................................................. 11
Warning Labels .................................................................................. 12
Procedural Labels .............................................................................. 13
Informational Labels ........................................................................... 14
Troubleshooting Voltage Issues
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
Table of Contents
Charging the Generator with 9-Volt Battery ....................................... 16
Checking the Stator Windings ............................................................ 17
Checking the Rotor Windings ............................................................. 19
Checking the Brushes ........................................................................ 21
Checking the Excitation Winding ........................................................ 22
Checking the AVR’s Sensing Wires ................................................... 24
Checking the Main Circuit Breaker ..................................................... 27
Checking the Voltage Selector Switch (VSS) ..................................... 29
Checking the Auto Idle Unity and Circuity .......................................... 30
Checking the Anti-Afterfire Solenoid .................................................. 37
Disassembly and Assembly
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
15
39
Tools Required for Disassembly/Assembly Procedures ..................... 39
Information Regarding Replacement Parts ........................................ 39
Information Regarding Reference Numbers ( ) .................................. 39
Information Regarding Threadlocking Compounds ............................ 39
Removing the Muffler ......................................................................... 40
Installing the Muffler ........................................................................... 42
Removing the Fuel Tank .................................................................... 44
Installing the Fuel Tank ...................................................................... 44
Removing the Stator ........................................................................... 45
Installing the Stator ............................................................................. 47
wc_br0171887en_002TOC.fm
5
Table of Contents
3.11
3.12
3.13
3.14
4
Removing the Rotor ............................................................................49
Installing the Rotor ..............................................................................50
Removing the Engine ..........................................................................51
Installing the Engine ............................................................................52
Schematics
4.1
4.2
4.3
4.4
4.5
4.6
5
GV Generators
54
Electrical Schematic—GV 2500A ........................................................54
Electrical Components—GV 2500A ....................................................55
Electrical Schematic—GV 3800A ........................................................56
Electrical Components—GV 3800A ....................................................57
Electrical Schematic—GV 5600A, GV 6600A .....................................58
Electrical Components—GV 5600A, GV 6600A ..................................59
Technical Data
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
60
Generator—GV 2500A ........................................................................60
Engine—GV 2500A .............................................................................61
Generator—GV 3800A ........................................................................62
Engine—GV 3800A .............................................................................63
Generator—GV 5600A ........................................................................64
Engine—GV 5600A .............................................................................65
Generator—GV 6600A ........................................................................66
Engine—GV 6600A .............................................................................68
wc_br0171887en_002TOC.fm
6
GV Generators
1
1.1
Safety Information
Safety Information
Callouts Found in this Manual
This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f Obey all safety messages that follow this symbol to avoid injury or death.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f Obey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION indicates a situation which, if not avoided, could result in minor or moderate injury.
f Obey all safety messages that follow this symbol to avoid possible minor or
moderate injury.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
wc_si000245gb.fm
7
Safety Information
1.2
GV Generators
Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
„ Read and understand the operating instructions contained in all manuals
delivered with the machine.
„ Familiarize yourself with the location and proper use of all controls and safety
devices.
„ Contact Wacker Neuson Corporation for additional training if necessary.
When operating this machine:
„ Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Guidelines for
machine
devices
„
„
„
„
„
„
Guidelines for
operation
„
„
„
„
„
„
Guidelines for
work space
„
„
„
„
„
„
wc_si000245gb.fm
ALWAYS operate the machine with all safety devices and guards in place and in
working order.
NEVER modify or defeat safety devices.
NEVER operate the machine if any safety devices or guards are missing or
inoperative.
ALWAYS check that all controls are functioning properly immediately after startup! DO NOT operate the machine unless all controls operate correctly.
NEVER use accessories or attachments that are not recommended by Wacker
Corporation. Damage to the machine and injury to the user may result.
NEVER use worn electrical cords. Severe electrical shock and equipment damage may result.
NEVER enclose or cover the generator when it is in use or when it is hot.
NEVER overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
NEVER attach equipment to the machine when it is suspended.
NEVER stand under the machine while it is being lifted or moved.
ALWAYS remove all tools, cords, and other loose items from the generator
before starting it.
ALWAYS make certain the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
NEVER operate the generator when open containers of fuel, paint, or other
flammable liquids are near.
NEVER run the electrical cords under the generator or over the top of the generator.
ALWAYS store the machine properly when it is not being used. The machine
should be stored in a clean, dry location out of the reach of children.
ALWAYS position and operate the generator when it is on a firm, noncombustible, level surface.
ALWAYS keep the area immediately surrounding and underneath the machine
clean, neat, and free of debris and combustible materials.
ALWAYS keep the area above the machine clear of debris that could fall on the
machine.
8
GV Generators
Standards for
operator
„
„
„
1.3
Safety Information
NEVER operate the generator, or tools attached to the generator, when your
hands are wet.
NEVER allow untrained personnel to operate the generator.
NEVER stand on the machine.
Safety Guidelines while Using Internal Combustion Engines
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety guidelines could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
Guidlines for
running the
engine
„
„
„
„
„
Guidelines for
refueling the
engine
„
„
„
„
„
„
„
wc_si000245gb.fm
NEVER use this generator inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and
vents. Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or smell.
NEVER use a generator inside an enclosed area such as a tunnel or a trench.
DO NOT smoke while operating the machine.
DO NOT run the engine near open flames.
NEVER touch the engine or muffler while the engine is on or immediately after it
has been turned off. These areas get hot and may cause burns.
NEVER smoke when refueling the engine.
DO NOT refuel a hot or running engine.
DO NOT refuel the engine near an open flame.
DO NOT spill fuel when refueling the engine.
ALWAYS refill the fuel tank in a well-ventilated area.
ALWAYS replace the fuel tank cap after refueling.
ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines
are loose.
9
Safety Information
1.4
GV Generators
Safety Guidelines for Maintaining the Machine
WARNING
CAUTION! Poorly maintained equipment can become a safety hazard! In order for the
equipment to operate safely and properly over a long period of time, periodic maintenance
and occasional repairs are necessary.
f Attach a “DO NOT START” sign to the control panel to notify other people of its condition whenever the machine is being serviced.
„
„
„
„
„
„
„
Guidelines for
lifting
„
„
Guidelines for
spare parts
„
„
„
wc_si000245gb.fm
NEVER use gasoline or other types of fuels or flammable solvents to clean
parts. Fumes from fuels and solvents can become explosive.
ALWAYS keep the fuel lines in good condition and properly connected.
NEVER attempt to clean the machine while it is running.
DO NOT allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
DO NOT allow untrained personnel to maintain this equipment. Only trained
electrical technicians should be allowed to maintain the electrical components of
this machine.
ALWAYS allow the engine to cool before transporting or maintaining it.
ALWAYS replace the safety devices and guards after repairs and maintenance.
ALWAYS make sure slings, chains, hooks, ramps, jacks and other types of lifting
devices are attached securely and have enough weight-bearing capacity to lift
or hold the machine safely.
Always remain aware of the location of other people nearby when lifting the
machine.
ALWAYS replace worn or damaged components with spare parts designed and
recommended by Wacker Corporation.
ALWAYS keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions and warn of
dangers and hazards.
DO NOT modify the machine without the express written approval of the manufacturer.
10
GV Generators
1.5
Safety Information
Label Locations
wc_gr005497
wc_si000245gb.fm
11
Safety Information
1.6
GV Generators
Warning Labels
Label
Definition
DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.
WARNING!
Hot surface!
Improper connection of generator to a
building’s electrical system can allow
electrical current from the generator to
backfeed into utility lines. This may result
in electrocution of utility workers, fire, or
explosion. Connections to a building’s
electrical system must be made by a
qualified electrician and comply with all
applicable laws and electrical codes.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or
smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are open.
Only use OUTSIDE and far away from
windows, doors, and vents.
wc_si000245gb.fm
12
GV Generators
1.7
Safety Information
Procedural Labels
CAUTION!
Use only clean, filtered gasoline fuel.
Check the fuel level.
Open the fuel flow valve.
Close the choke.
Turn the engine switch to the ON position.
Pull the rewind starter.
Open the choke.
wc_si000245gb.fm
13
Safety Information
GV Generators
Turn the engine switch to “OFF”.
Close the fuel flow valve.
Electrical ground
1.8
Informational Labels
A nameplate listing the model number,
item number, revision number, and serial
number is attached to each unit. Please
record the information found on this plate
so it will be available should the
nameplate become lost or damaged.
When ordering parts or requesting
service information, you will always be
asked to specify the model number, item
number, revision number, and serial
number of the unit.
wc_si000245gb.fm
14
GV Generators
2
Troubleshooting Voltage Issues
Troubleshooting Voltage Issues
Prerequisites
„
„
Procedure
Generator must be able to start
Multimeter
To determine where to begin troubleshooting voltage issues, follow the procedure
below.
1. Remove the end cap (a) from the generator.
V
F
1000
200
20
V
2
200m
A
V-
COM
wc_gr004336
WARNING! Electric shock hazard. High voltage exists at the alternator. Electric shock can
cause severe injury or death.
f Never touch the alternator components or the wires of the generator when the engine is
running.
2. Start the engine.
3. Place the auto idle switch in the OFF position.
4. Measure the voltage between the red and yellow wires; also measure between
the black and green wires.
Sequence
If
Then
Between 100–140 VAC is measured in both
locations
All other cases
Start with step 6.
Follow the sequence below when troubleshooting:
Step
1.
2.
3.
4.
5.
6.
7.
8.
wc_tx000772gb.fm
Start with step 1.
Test charge the generator with a 9-Volt battery.
Check the stator windings.
Check the rotor windings.
Check the brushes.
Check the excitation winding.
Check AVR sensing wires.
Check main circuit breaker.
Check the voltage selector switch.
15
Topic
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Troubleshooting Voltage Issues
2.1
GV Generators
Charging the Generator with 9-Volt Battery
Prerequisites
„
„
Procedure
9-Volt battery
Multimeter
Follow the procedure below to test charge the generator with a 9-Volt battery.
1. Remove the end cap (a) from the generator.
2. Disconnect the wiring at the connector to the automatic voltage regulator (AVR)
(b).
3. Disconnect the wiring to the brushes.
4. Connect a 9-Volt battery to the brushes—this is a polarity-sensitive connection
so be certain to connect battery positive to the positive brush.
V
+ –
9V
F
1000
200
20
V
2
200m
A
V-
COM
wc_gr004395
5. Start the engine.
6. Measure the AC voltage between the red and yellow wires at the terminal strip.
Is 18–65 VAC measured?
Yes ____
No ____
Continue troubleshooting by
checking the stator windings.
The AVR has failed, replace it.
The procedure to test charge the generator is now complete.
Disconnect the 9-Volt battery and continue troubleshooting.
wc_tx000772gb.fm
16
Your reading
GV Generators
2.2
Troubleshooting Voltage Issues
Checking the Stator Windings
Prerequisites
„
„
Procedure
Generator shut down
Multimeter
Follow the procedure below to check the stator windings.
1. Remove the end cap (a) from the generator.
2. Disconnect the yellow (Y), red (R), black (B), and green (G) wires from the alternator.
3. Measure the resistance in Ohms between the red and yellow wires. Also measure between the black and green wires. See chart below.
Machine
R–Y
B–G
GV 2500A
0.9–1.4
0.9–1.4
GV 3800A
0.7–1.2
0.7–1.2
GV 5600A
0.4–0.9
0.4–0.9
GV 6600A
0.3–0.8
0.3–0.8
Is the correct resistance measured for your machine?
Yes ____
No ____
Continue.
The stator windings have failed. Replace the stator.
This procedure continues on the next page.
wc_tx000772gb.fm
17
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
4. Check each winding to ground. Measure the resistance between each post
where the yellow (Y), red (R), black (B), and green (G) wires were connected
and the ground stud.
Is any resistance measured for any of the checks?
Result
Yes ____
No ____
The stator windings have failed. Replace the stator.
Continue.
The procedure to check the stator windings is now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
wc_tx000772gb.fm
18
GV Generators
2.3
Troubleshooting Voltage Issues
Checking the Rotor Windings
Prerequisites
„
„
Procedure
Generator shut down
Multimeter
Follow the procedure below to check the rotor winding.
1. Remove the end cap (a) from the generator.
sdfdsf
2. Remove the screw that secures the brushes (b) and remove the brushes.
3. Measure the resistance of the rotor winding by measuring across the slip rings
(c).
GP 2500:
GP 3800:
GP 5600:
GP 6600:
c
51–53
47–49
57–59
59–61
F
1000
200
20
V
2
200m
A
V-
COM
wc_gr004340
Is the correct resistance measured for your model?
Yes ____
No ____
Continue.
The rotor winding has failed. Replace the rotor.
This procedure continues on the next page.
wc_tx000772gb.fm
19
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
4. Check for shorts to the rotor shaft by measuring resistance between each slip
ring and the end of the rotor shaft.
Is any resistance measured for either of the checks?
Yes ____
No ____
The rotor winding has failed. Replace the rotor.
The rotor winding is
OK.
5. Re-install the brushes—do not overtighten the screws.
6. Re-install the end cap.
Result
The procedure to check the rotor winding is now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
wc_tx000772gb.fm
20
GV Generators
2.4
Troubleshooting Voltage Issues
Checking the Brushes
Prerequisites
„
„
Procedure
Generator shut down
Multimeter
Follow the procedure below to check the brushes.
1. Remove the end cap (a) from the generator.
sdfdsf
2. Remove the screw that secures the brush holder (b) and remove the brush
holder.
3. Measure the length of the brush protruding from the brush holder. The minimum
allowable length is 6.5 mm (0.25 in.).
6.5
mm
wc_gr004341
4. Measure the continuity of each brush.
Does each brush measure at least 6.5 mm and have continuity?
Yes ____
No ____
The brushes are OK
The brushes have failed. Replace
the brushes.
Your reading
5. Re-install the brush holder—do not overtighten the screw.
6. Re-install the end cap.
The procedure to check the brushes is now complete.
If the problem has not been resolved, continue with checking the excitation winding.
wc_tx000772gb.fm
21
Troubleshooting Voltage Issues
2.5
GV Generators
Checking the Excitation Winding
Prerequisites
„
„
Procedure
Generator shut down
Multimeter
Follow the procedure below to check the excitation winding.
1. Remove the end cap (a) from the generator.
2. Disconnect the plug (b) which connects the excitation winding to the Automatic
Voltage Regulator (AVR).
3. Measure the resistance of the excitation winding by measuring across the two
yellow (Y) wires of the connector.
Is the correct resistance measured for your model?
Yes ____
No ____
Continue.
The excitation winding has failed.
Replace the stator.
This procedure continues on the next page.
wc_tx000772gb.fm
22
Your reading
GV Generators
Troubleshooting Voltage Issues
Continued from the previous page.
4. Check each side of the winding to ground by Measuring the resistance between
each yellow wire and the ground stud.
Is any resistance measured for either of the checks?
Yes ____
No ____
The excitation winding has failed. Replace the stator.
Continue.
5. Reconnect the wiring.
6. Re-install the end cap.
Result
wc_tx000772gb.fm
The procedure to check the excitation winding is now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
23
Troubleshooting Voltage Issues
2.6
GV Generators
Checking the AVR’s Sensing Wires
Prerequisites
„
„
Procedure
Generator shut down
Multimeter
Follow the procedure below to check the Automatic Voltage Regulator (AVR) sensing wires.
1. Remove the end cap (a) from the generator.
2. Disconnect the white (W), red (R), gray (Gr), and light green (LG) wires from the
generator terminal strip.
3. Disconnect the AVR at the wiring harness connector (b).
4. Check the continuity between the brown (Br) wire of the wiring harness connector (b) and the yellow wire (Y) of the generator.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Replace the stator.
This procedure continues on the next page.
wc_tx000772gb.fm
24
GV Generators
Troubleshooting Voltage Issues
Continued from the previous page.
5. Check the resistance between the brown (Br) wire of the wiring harness connector (b) and the ground stud (x).
Is any resistance measured?
Yes ____
No ____
The sensing wire has failed. Replace the stator.
Continue.
6. Disconnect the 6-wire connector (c).
7. Check for continuity between the light green (LG) wire of the 6-wire connector
and the black (B) wire of the generator.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Replace the stator.
8. Check the resistance between the light green (LG) wire of the wiring harness 6wire connector (c) and the ground stud (x).
Is any resistance measured?
Yes ____
No ____
The sensing wire has failed. Replace the stator.
Continue.
9. Check for continuity between the red-white (R/W) wire of the 6-wire connector
and the red (R) wire of the generator.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Replace the stator.
This procedure continues on the next page.
wc_tx000772gb.fm
25
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
10.Open the control panel to access the Voltage Selector Switch (VSS) (d).
11.Check the continuity of the red-white (RW) wire from the 6-wire connector (e) to
the VSS (d).
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Repair the RW wire.
12.Check the continuity of the gray (GR) wire between the 6-wire connector and
the VSS.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Repair the GR wire.
13.Check the continuity of the light green (LG) wire between the 6-wire connector
and the VSS.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Repair the LG wire.
14.Disconnect the 4-wire plug from the automatic voltage regulator (AVR).
15.Check the continuity of the blue (L) wire from the 4-wire connector to the 6-wire
connector.
Does the wiring have continuity?
Yes ____
No ____
Continue.
The wiring has failed. Repair the L wire.
16.Reconnect the wiring and reassemble the generator.
Result
wc_tx000772gb.fm
The procedure to check the AVR sensing wires is now complete.
26
GV Generators
2.7
Troubleshooting Voltage Issues
Checking the Main Circuit Breaker
Prerequisites
Multimeter
Procedure
Follow the procedure below to check the main circuit breaker.
1. Remove the screws (a) that secure the control panel to the frame. Once
removed, lower the control panel to access screws (b).
2. Remove the screws (b) that secure the front and back halves of the control
panel.
3. Position the front half of the control panel to access the main circuit breaker (c).
4. Place the auto idle switch in the OFF position.
WARNING! Electric shock hazard. High voltage exists at the components of the control
panel when the engine is running. Electric shock can cause severe injury or death.
f Never touch any control panel component with your bare hands when the engine is running.
5. Start the engine.
This procedure continues on the next page.
wc_tx000772gb.fm
27
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
6. Measure the voltage between the red (R) wire at the main circuit breaker and a
common ground; then at the blue (L) wire and a common ground.
Is 110–130V measured in each case?
Yes ____
No ____
The main circuit breaker is receiving voltage; continue.
Your reading
The main circuit breaker is not
receiving voltage. Shut down the
engine and check the wiring.
7. Place the main circuit breaker in the ON position.
8. Check the outgoing voltage from the main circuit breaker by measuring the voltage between the red wire and a common ground; then at the blue wire and a
common ground.
Is 110–130V measured in each case?
Yes ____
No ____
The main circuit breaker is OK.
The main circuit breaker has failed;
replace it.
The procedure to check the main circuit breaker is now complete.
Reassemble the generator.
wc_tx000772gb.fm
28
Your reading
GV Generators
2.8
Troubleshooting Voltage Issues
Checking the Voltage Selector Switch (VSS)
Prerequisites
Multimeter
Procedure
Follow the procedure below to check the Voltage Selector Switch (VSS).
1. Remove the screws (a) that secure the control panel to the frame. Once
removed, lower the control panel to access screws (b).
2. Remove screws (b) that secure the front and back halves of the control panel.
3. Position the front half of the control panel to access the VSS (c).
4. Remove the two wiring connectors (d) from the VSS.
5. Check the VSS for continuity as shown below.
1
5
9
Position
2
6
10
Terminals
with
continuity
3
4
7
8
11
120V 120/240V
1–5
5–9
2–6
6–10
3–7
7–11
4–8
8–12
12
wc_gr004368
Does the VSS function properly?
Yes ____
No ____
The VSS is OK.
The VSS has failed; replace it.
6. Reassemble the generator.
The procedure to check the VSS is now complete.
wc_tx000772gb.fm
29
Your reading
Troubleshooting Voltage Issues
2.9
GV Generators
Checking the Auto Idle Unity and Circuity
Prerequisites
Multimeter
Procedure
Follow the procedure below to check the auto idle circuitry.
1. Remove the end cap (d) from the generator.
2. Disconnect the 6-wire connector (e).
3. Measure the resistance across the two gray wires of the 6-pin connector.
Is the correct resistance measured for your machine?
Yes ____
No ____
Continue.
The auxiliary winding has failed.
Call Wacker Service.
This procedure continues on the next page.
wc_tx000772gb.fm
30
Your reading
GV Generators
Troubleshooting Voltage Issues
Continued from the previous page.
4. Disconnect the DC rectifier (z).
z
F
1000
200
20
V
y
2
200m
A
V-
d
COM
wc_gr004372
wc_gr004370
5. Check across the terminals of the DC rectifier using the diode scale. Use the
terminal (y) where the BR-R wire connects as a base point. Measure between it
and the two other terminals. Reverse the leads of the meter and measure
again. The meter should read approximately 0.5V in one direction and OPEN or
“OL” in the other.
Does the DC rectifier function as stated above?
Yes ____
No ____
The DC rectifier is OK; continue.
The DC rectifier has failed;
replace it.
This procedure continues on the next page.
wc_tx000772gb.fm
31
Your reading
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
6. Remove the screws (a) that secure the control panel to the frame. Once
removed, lower the control panel to access the screws (b).
7. Remove the screws (b) that secure the front and back halves of the control
panel.
8. Position the front half of the control panel to access the auto idle unit (c).
This procedure continues on the next page.
wc_tx000772gb.fm
32
GV Generators
Troubleshooting Voltage Issues
Continued from the previous page.
WARNING! Electric shock hazard. High voltage exists at the components of the control
panel when the engine is running. Electric shock can cause severe injury or death.
f Never touch any control panel component with your bare hands when the engine is running.
9. Start the engine.
10.Measure the DC voltage between the black/red (B/R) wire at the connector and
the white/black (W/B) wire of the auto idle unit.
B/R
W/B
F
1000
200
20
V
2
200m
A
VDC
VDC
V-
COM
wc_gr004361
Is at least 9.8VDC measured?
Yes ____
No ____
Continue.
The wiring has failed. Check the continuity of the
B/R wire and the continuity of the W/B wire.
11.Shut down the engine.
This procedure continues on the next page.
wc_tx000772gb.fm
33
Your reading
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
12.Disconnect the auto idle switch (d) and check it for continuity. It should have
continuity in the Auto position and no continuty in the OFF position.
Is the auto idle switch OK?
Yes ____
No ____
Reconnect the auto idle switch and
continue.
Replace the auto idle switch.
Your reading
WARNING! Electric shock hazard. High voltage exists at the components of the control
panel when the engine is running. Electric shock can cause severe injury or death.
f Never touch any control panel component with your bare hands when the engine is running.
13.Start the engine.
14.Place the auto idle switch in the ON position.
This procedure continues on the next page.
wc_tx000772gb.fm
34
GV Generators
Troubleshooting Voltage Issues
Continued from the previous page.
15.Measure the DC voltage between the black (B) wire of the auto idle unit and the
white-black (W/B) wire of the auto idle unit.
Is at least 9.8VDC measured?
Yes ____
Continue.
No ____
Your reading
The wiring has failed. Shutdown engine and
check the continuity of the B wire and the continuity of the W/B wire.
16.Measure the DC voltage between the red/white (R) wire of the auto idle unit and
the white/black (W/B) wire of the auto idle unit.
Is at least 9.8VDC measured?
Yes ____
No ____
Continue.
The auto idle unit has failed. Call
Wacker Service.
This procedure continues on the next page.
wc_tx000772gb.fm
35
Your reading
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
17.Measure the voltage between the red (R) wire of the auto idle unit and the
white-black (W/B) wire of the auto idle unit.
Is at least 9.8VDC measured?
Yes ____
No ____
Continue.
The auto idle unit has failed. Call
Wacker Service.
Your reading
18.Place the main breaker in the ON position.
19.Connect a load to the generator.
20.Once again, measure the voltage between the red (R) wire of the auto idle unit
and the white-black (W/B) wire of the auto idle unit.
Is at least approximately 0 (zero) VDC measured?
Yes ____
No ____
The auto idle circuit is OK.
The auto idle unit has failed. Call
Wacker Service.
21.Reassemble the generator.
The procedure to check the auto idle circuitry is now complete.
wc_tx000772gb.fm
36
Your reading
GV Generators
2.10
Troubleshooting Voltage Issues
Checking the Anti-Afterfire Solenoid
Prerequisites
„
„
Procedure
Multimeter
Functioning DC Rectifier (See section Checking Auto Idle Unit and Circuitry.)
Follow the procedure below to check the Anti-Afterfire Solenoid (AAS).
1. Remove the screws (a) that secure the control panel to the frame. Once
removed, lower the control panel to access the screws (b).
2. Remove the screws (b) that secure the front and back halves of the control
panel.
3. Position the front half of the control panel to access the capacitor (c).
4. Remove the wiring from the capacitor.
5. Discharge the capacitor by placing a screwdriver across the two terminals.
This procedure continues on the next page.
wc_tx000772gb.fm
37
Troubleshooting Voltage Issues
GV Generators
Continued from the previous page.
6. Measure the capacitance of the capacitor.
Does the capacitor measure approximately 4700 ±10% micro Farads?
Yes ____
No ____
The capacitor is OK.
The capacitor has failed; replace it.
7. Reassemble the generator.
The procedure to check the AAS is now complete.
wc_tx000772gb.fm
38
Your reading
GV Generator Repair
3
3.1
Disassembly and Assembly
Tools Required for Disassembly/Assembly Procedures
„
„
„
3.2
It is up to the mechanic to use common sense and good judgment in tool
selection to reduce the risk of injury while repairing the machine.
In cases where a special tool is required, the special tool is listed in the
prerequisite section of the procedure.
Before substituting another tool or procedure from those recommended in this
manual, the mechanic must be satisfied that neither personal injury nor damage
to the machine will result due to the substitution.
Information Regarding Replacement Parts
„
„
„
„
„
3.3
Disassembly and Assembly
The repair procedures contained in this manual do not include part numbers.
For replacement parts information, refer to the Parts Book originally supplied
with the machine.
If the original Parts Book has been lost, a replacement may be ordered from
Wacker Neuson Corporation.
When ordering a replacement Parts Book, please list the model number, item
number, revision level, and serial number of the machine.
Parts Books are also available on the Wacker Neuson Corporation Web site.
See www.wackerneuson.com. Enter the site as a visitor.
Information Regarding Reference Numbers ( )
Repair procedures contain reference numbers enclosed in parentheses ( ). These
numbers refer to the item numbers shown on the assembly drawings and other
detailed drawings. They are included to aid the mechanic in identifying parts and
assembling components.
3.4
Information Regarding Threadlocking Compounds
Background
Due to the heavy vibration inherent in this type of equipment, the repair and service
procedures described in this manual specify the use of threadlocking compounds.
These compounds should be used where indicated to prevent the fasteners from
becoming loose.
Recommended Although Loctite® is referred to throughout this manual, any equivalent type of
threadlockers sealant such as Hernon®, Prolock, or Omnifit may be used. For a complete list of
recommended sealing and locking compounds, refer to the Use of Threadlockers
and Sealants chart at the end of this manual.
Applying
threadlockers
wc_tx000775gb.fm
Clean the screw threads and wipe off any oil or grease before applying a threadlocking compound.
39
Disassembly and Assembly
3.5
GV Generator Repair
Removing the Muffler
Prerequisites
Engine cool
Procedure
Follow the procedure below to remove the muffler.
1. Disconnect the spark plug.
2. Remove the fuel tank. See section Removing the Fuel Tank.
3. Remove the screws that secure the outer muffler guard and remove the outer
muffler guard (a).
a
4. Remove the screw (g) that secures the generator mounting leg to the shock
mount bracket.
5. Remove the screw (h) that secures the ground wire.
6. Remove the screw (i) that secures the muffler to the stator.
7. Remove the screws (b) that secure the muffler to the engine.
This procedure continues on the next page.
wc_tx000775gb.fm
40
GV Generator Repair
Disassembly and Assembly
Continued from the previous page.
8. Lift the muffler and the muffler guard from the engine and frame.
wc_gr004408
The procedure to remove the muffler is now complete.
wc_tx000775gb.fm
41
Disassembly and Assembly
3.6
GV Generator Repair
Installing the Muffler
Prerequisites
Engine cool
Procedure
Follow the procedure below to install the muffler.
1. Position the muffler and the muffler guard into the frame and onto the engine.
wc_gr004408
2. Remove the screws (b) that secure the muffler to the engine.
3. Install the screw (i) that secures the muffler to the stator.
4. Install the screw (g) that secures the generator mounting leg to the shock mount
bracket.
5. Install the screw (h) that secures the ground wire.
This procedure continues on the next page.
wc_tx000775gb.fm
42
GV Generator Repair
Disassembly and Assembly
Continued from the previous page.
6. Remove the screws that secure the outer muffler guard and remove the outer
muffler guard (a).
a
7. Install the fuel tank. See section Installing the Fuel Tank.
The procedure to install the muffler is now complete.
wc_tx000775gb.fm
43
Disassembly and Assembly
3.7
GV Generator Repair
Removing the Fuel Tank
Prerequisites
Machine shut down
Procedure
Follow the procedure below to remove the fuel tank.
1. Disconnect the spark plug.
2. Close the fuel valve.
3. Disconnect the fuel hose (a) from fuel valve.
a
b
wc_gr004397
4. Remove the screws (b) that secure the tank and brace to the fuel frame and pull
the fuel tank from the frame.
5. Remove the brace from the fuel tank.
The procedure to remove the fuel tank is now complete.
3.8
Installing the Fuel Tank
Prerequisites
Machine shut down
Procedure
Follow the procedure below to install the fuel tank.
1. Install the brace to the fuel tank.
2. Position the fuel tank into the frame and secure it with screws (b).
a
b
wc_gr004397
3. Connect the fuel hose (a) to the fuel valve.
The procedure to install the fuel tank is now complete.
wc_tx000775gb.fm
44
GV Generator Repair
3.9
Disassembly and Assembly
Removing the Stator
Prerequisites
Machine shut down
Procedure
Follow the procedure below to remove the stator.
1. Disconnect the spark plug.
2. Remove the end cover (a).
d
e
c
b
wc_gr004398
3. Disconnect the wiring from the terminal strip (b), the ground wire (c), and the
harness connector (d). On GV 2500 machines, disconnect the generator plug
(e).
4. Remove the brush holder (f).
5. Remove the screw (g) that secures the generator mounting leg to the shock
mount bracket.
6. Remove the screw (h) that secures the ground wire.
This procedure continues on the next page.
wc_tx000775gb.fm
45
Disassembly and Assembly
GV Generator Repair
Continued from the previous page.
7. Remove the screw (i) that secures the muffler to the stator.
8. Remove the four long screws (j) that secure the stator to the machine.
9. Pull the stator (k) from the machine.
The procedure to remove the stator is now complete.
wc_tx000775gb.fm
46
GV Generator Repair
3.10
Disassembly and Assembly
Installing the Stator
Prerequisites
Machine shut down
Procedure
Follow the procedure below to install the stator.
1. Position the stator over the rotor and onto the machine.
2. Secure the stator to the machine with the four long screws (j).
3. Install the screw (i) that secures the muffler guard to the stator.
4. Install the screw (h) that secures the ground wire.
5. Install the screw (g) that secures the generator mounting leg to the shock mount
bracket.
This procedure continues on the next page.
wc_tx000775gb.fm
47
Disassembly and Assembly
GV Generator Repair
Continued from the previous page.
6. Install the brush holder (f).
d
e
c
b
wc_gr004398
7. Connect the wiring to the terminal strip (b), the ground wire (c), and the harness
connector (d). On GV 2500 machines, connect the generator plug (e).
8. Re-install the end cover (a).
The procedure to install the stator is now complete.
wc_tx000775gb.fm
48
GV Generator Repair
3.11
Disassembly and Assembly
Removing the Rotor
Prerequisites
Oil filter wrench
Procedure
Follow the procedure below to remove the rotor.
1. Disconnect the spark plug.
2. Remove the stator. See section Removing the Stator.
3. Loosen the long bolt (a) that secures the rotor to the engine. To prevent the
rotor from spinning, secure the rotor with an oil filter wrench when removing the
long bolt.
4. Support the rotor with one hand then strike the rotor with a rubber hammer
repeatedly while rotating the rotor until it comes free of the engine shaft.
NOTICE: Do not strike the winding wires or the magnet (c). Damage to the rotor
may occur.
5. Remove the long bolt and the rotor from the engine.
The procedure to remove the rotor is now complete.
wc_tx000775gb.fm
49
Disassembly and Assembly
3.12
GV Generator Repair
Installing the Rotor
Prerequisites
Oil filter wrench
Procedure
Follow the procedure below to install the rotor.
1. Position the rotor on the engine shaft.
2. Install the long bolt (a) that secures the rotor to the engine. To prevent the rotor
from spinning, secure the rotor with an oil filter wrench when installing the long
bolt.
The procedure to install the rotor is now complete.
wc_tx000775gb.fm
50
GV Generator Repair
3.13
Disassembly and Assembly
Removing the Engine
Prerequisites
Engine cool
Procedure
Follow the procedure below to remove the engine.
1. Disconnect the spark plug.
2. Label and disconnect the wiring between the engine and the control panel.
3. Remove the fuel tank. See section Removing the Fuel Tank.
4. Remove the muffler. See section Removing the Muffler.
5. Remove the stator. See section Removing the Stator.
6. Remove the rotor. See section Removing the Rotor.
7. Remove the screws (a) that secure the engine to the shock mounts.
8. Pull the engine from the frame.
The procedure to remove the engine is now complete.
wc_tx000775gb.fm
51
Disassembly and Assembly
3.14
GV Generator Repair
Installing the Engine
Prerequisites
Engine cool
Procedure
Follow the procedure below to install the engine.
1. Position the engine into the frame and secure it to the shock mounts with screws
(a).
2. Install the rotor. See section Installing the Rotor.
3. Install the stator. See section Installing the Stator.
4. Install the muffler. See section Installing the Muffler.
5. Install the fuel tank. See section Installing the Fuel Tank.
6. Connect the wiring between the engine and the control panel.
The procedure to install the engine is now complete.
wc_tx000775gb.fm
52
GV Generator Repair
Disassembly and Assembly
Notes
wc_tx000775gb.fm
53
Schematics
4
Schematics
Electrical Schematic—GV 2500A
3
A
14
4
1
2
12
B
C
5
13
11
6
10
9
7
8
4.1
GV Generator Repair
wc_tx000813gb.fm
54
GV Generator Repair
4.2
Schematics
Electrical Components—GV 2500A
Ref.
Description
A
Generator
Ref.
Description
Ref.
Description
Ref.
B
Control Box
C
Ref.
Description
Engine
Description
1
Main stator winding
8
Engine ON-OFF switch
2
Secondary winding
9
Oil alert module
3
Rotor winding
10
Oil level switch
4
Automatic voltage regulator
11
Ignition coil
5
20A circuit breaker
12
Ground terminal
6
GFI duplex receptacle—125V
13
Spark plug
7
Duplex receptacle—125V
14
Slip ring
Wire Colors
wc_tx000813gb.fm
B
Black
V
Violet
Or
Orange
G
Green
W
White
Pr
Purple
L
Blue
Y
Yellow
Sh
Shield
P
Pink
Br
Brown
LL
Light Blue
R
Red
Cl
Clear
G/Y
T
Tan
Gr
Gray
55
Green/Yellow
Schematics
Electrical Schematic—GV 3800A
3
A
14
4
1
2
22
12
23
B
15
C
16
13
18
11
5
10
21
17
9
20
8
6
6
19
4.3
GV Generator Repair
wc_tx000813gb.fm
56
GV Generator Repair
4.4
Schematics
Electrical Components—GV 3800A
Ref.
Description
A
Generator
Ref.
Description
Ref.
Description
Ref.
B
Control Box
C
Ref.
Description
Engine
Description
1
Main stator winding
13
Spark plug
2
Secondary winding
14
Slip ring
3
Rotor winding
15
Auto idle unit
4
Automatic voltage regulator
16
Voltage selector switch
5
20A circuit breaker
17
Twist lock receptacle—125/250V
6
GFI duplex receptacle—125V
18
Auto idle switch
7
---
19
Idle solenoid
8
Engine ON-OFF switch
20
Capacitor
9
Oil alert module
21
Fuel stop solenoid
10
Oil level switch
22
Auxiliary winding
11
Ignition coil
23
DC rectifier
12
Ground terminal
-
---
Wire Colors
wc_tx000813gb.fm
B
Black
V
Violet
Or
Orange
G
Green
W
White
Pr
Purple
L
Blue
Y
Yellow
Sh
Shield
P
Pink
Br
Brown
LL
Light Blue
R
Red
Cl
Clear
G/Y
T
Tan
Gr
Gray
57
Green/Yellow
Schematics
Electrical Schematic—GV 5600A, GV 6600A
3
A
14
4
1
2
22
23
12
B
15
21
C
16
13
18
11
5
10
17
9
20
24
8
6
6
19
4.5
GV Generator Repair
wc_tx000813gb.fm
58
GV Generator Repair
4.6
Schematics
Electrical Components—GV 5600A, GV 6600A
Ref.
Description
A
Generator
Ref.
Description
Ref.
Description
Ref.
B
Control Box
C
Ref.
Description
Engine
Description
1
Main stator winding
13
Spark plug
2
Secondary winding
14
Slip ring
3
Rotor winding
15
Auto idle unit
4
Automatic voltage regulator
16
Voltage selector switch
5
Main circuit breaker
17
Twist lock receptacle—125/250V
6
GFI duplex receptacle—125V
18
Auto idle switch
7
---
19
Idle solenoid
8
Engine ON-OFF switch
20
Capacitor
9
Oil alert module
21
Fuel stop solenoid
10
Oil level switch
22
Auxiliary winding
11
Ignition coil
23
DC rectifier
12
Ground terminal
24
Twist lock receptacle—125V
Wire Colors
wc_tx000813gb.fm
B
Black
V
Violet
Or
Orange
G
Green
W
White
Pr
Purple
L
Blue
Y
Yellow
Sh
Shield
P
Pink
Br
Brown
LL
Light Blue
R
Red
Cl
Clear
G/Y
T
Tan
Gr
Gray
59
Green/Yellow
Technical Data
5
GV Generators
Technical Data
5.1
Generator—GV 2500A
Item No.
GV 2500A
0620286 0620542
Generator
Maximum output
W
2500
Continuous output
W
2250
Type
AC voltages available
Frequency
Single phase,
self-exciting, 2-pole, field rotating
120
1
Volts
phase
Hz
60
cos ø
1.0
AC receptacles:
125V GFI duplex
125V duplex
Amp
Amp
20
20
Main circuit breaker
Amp
20
Power factor
LxWxH
mm (in.)
625 x 440 x 490 (24.5 x 17.2 x 19.3)
Weight (dry)
kg (lbs.)
45 (99.2)
wc_td000248gb.fm
60
GV Generators
5.2
Technical Data
Engine—GV 2500A
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No.
GV 2500A
0620286 0620542
Engine
Engine make
Honda
Engine model
GX 160 K1
Maximum rated power
at rated speed
3.6 (4.8) @ 3600 rpm
kW (Hp)
Spark plug
Electrode gap
BPR6ES (NKG)
0.7–0.8 (0.028–0.031)
mm (in.)
Operating speed
rpm
3600
Air cleaner
type
Oil-wetted foam
EnginelLubrication
oil grade
Engine oil capacity
l (qts.)
Fuel
SAE 10W30 service class SF or SG
0.6 (0.7)
Regular unleaded gasoline
type
Fuel tank capacity
l (gal.)
14 (3.7)
Fuel consumption
l (qts.)/hr.
1.5 (1.6)
Running time continuous load
wc_td000248gb.fm
9.7
hrs.
61
Technical Data
5.3
GV Generators
Generator—GV 3800A
Item No.
GV 3800A
0620287
Generator
Maximum output
W
3800
Continuous output
W
3400
Type
AC voltages available
Frequency
Power factor
AC receptacles:
125V GFI duplex (2)
125/250V twist lock
Main circuit breaker
(two pole)
Single phase,
self-exciting, 2-pole, field rotating
120/240
1
Volts
phase
Hz
60
cos ø
1.0
Amp
Amp
20
20
Amp
16 per pole
LxWxH
mm (in.)
710 x 550 x 515 (28.0 x 21.6 x 20.3)
Weight (dry)
kg (lbs.)
65 (143.3)
wc_td000248gb.fm
62
GV Generators
5.4
Technical Data
Engine—GV 3800A
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No.
GV 3800A
0620287
0620334
0620409
Engine
Engine make
Honda
Engine model
GX 240 K1
Maximum rated power
at operating speed
5.3 (7.1) @ 3600 rpm
kW (Hp)
Spark plug
Electrode gap
BPR6ES (NKG)
0.7–0.8 (0.028–0.031)
mm (in.)
Operating speed
rpm
3600
Air cleaner
type
Oil-wetted foam
Engine lubrication
Engine oil capacity
Fuel
oil grade
SAE 10W30 service class SF or SG
1.1 (1.2)
l (qts.)
Regular unleaded gasoline
type
Fuel tank capacity
l (gal.)
21 (5.5)
Fuel consumption
l (qts.)/hr.
2.4 (2.5)
Running time continuous load
wc_td000248gb.fm
8.8
hrs.
63
Technical Data
5.5
GV Generators
Generator—GV 5600A
Item No.
GV 5600A
0620288
0620335
0620410
Generator
Maximum output
W
5600
Continuous output
W
5000
Type
AC voltages available
Frequency
Power factor
AC receptacles:
125V GFI duplex (2)
125V twist lock
125/250V twist lock
Main circuit breaker
(two pole)
Single phase,
self-exciting, 2-pole, field rotating
120/240
1
Volts
phase
Hz
60
cos ø
1.0
Amp
Amp
Amp
20
30
30
Amp
15 per pole
LxWxH
mm (in.)
710 x 550 x 515 (28.0 x 21.6 x 20.3)
Weight (dry)
kg (lbs.)
78 (172)
wc_td000248gb.fm
64
GV Generators
5.6
Technical Data
Engine—GV 5600A
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No.
GV 5600A
0620288
0620335
0620410
Engine
Engine make
Honda
Engine model
GX 340 K1
Maximum rated power
at rated speed
7.1 (9.5) @ 3600 rpm
kW (Hp)
Spark plug
Electrode gap
BPR6ES (NKG)
0.7–0.8 (0.028–0.031)
mm (in.)
Operating speed
rpm
3600
Air cleaner
type
Oil-wetted foam
Engine lubrication
Engine oil capacity
Fuel
oil grade
SAE 10W30 service class SF or SG
1.1 (1.2)
l (qts.)
Regular unleaded gasoline
type
Fuel tank capacity
l (gal.)
21 (5.5)
Fuel consumption
l (qts.)/hr.
3.5 (3.7)
Running time continuous load
wc_td000248gb.fm
6.2
hrs.
65
Technical Data
5.7
GV Generators
Generator—GV 6600A
Item No.
GV 6600A
0620289
Generator
Maximum output
W
6600
Continuous output
W
6000
Type
AC voltages available
Frequency
Power factor
AC receptacles:
125V GFI duplex (2)
125/250V twist lock
125V twist lock
Main circuit breaker
(two pole)
Single phase,
self-exciting, 2-pole, field rotating
120/240
1
Volts
phase
Hz
60
cos ø
1.0
Amp
Amp
Amp
20
30
30
Amp
15 per pole
LxWxH
mm (in.)
710 x 550 x 515 (28.0 x 21.6 x 20.3)
Weight (dry)
kg (lbs.)
80 (176.4)
wc_td000248gb.fm
66
GV Generators
Technical Data
Item No.
GV 6600A
0620336
Generator
Maximum output
W
6600
Continuous output
W
6000
Type
AC voltages available
Frequency
Power factor
AC receptacles:
125V GFI duplex (2)
125/250V twist lock
125V twist lock
Main circuit breaker
(two pole)
Single phase,
self-exciting, 2-pole, field rotating
120/240
1
Volts
phase
Hz
60
cos ø
1.0
Amp
Amp
Amp
20
30
30
Amp
15 per pole
LxWxH
mm (in.)
710 x 550 x 515 (28.0 x 21.6 x 20.3)
Weight (dry)
kg (lbs.)
80 (176.4)
wc_td000248gb.fm
67
Technical Data
5.8
GV Generators
Engine—GV 6600A
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No.
GV 6600A
0620289
Engine
Engine make
Honda
Engine model
GX 390 K1
Max. rated power @
rated speed
8.2 (11.0) @ 3600 rpm
kW (Hp)
Spark plug
Electrode gap
BPR6ES (NKG)
0.7–0.8 (0.028–0.031)
mm (in.)
Operating speed
rpm
3600
Air cleaner
type
Oil-wetted foam
Engine lubrication
Engine oil capacity
Fuel
oil grade
SAE 10W30 service class SF or SG
1.1 (1.2)
l (qts.)
Regular unleaded gasoline
type
Fuel tank capacity
l (gal.)
26 (6.8)
Fuel consumption
l (qts.)/hr.
3.9 (4.1)
Running time continuous load
wc_td000248gb.fm
6.7
hrs.
68
GV Generators
Technical Data
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No.
GV 6600A
0620336
Engine
Engine make
Honda
Engine model
GX 390 R1
Max. rated power @
rated speed
9.7 (13) @ 3600 rpm
kW (Hp)
Spark plug
Electrode gap
BPR6ES (NKG)
0.7–0.8 (0.028–0.031)
mm (in.)
Operating speed
rpm
3600
Air cleaner
type
Oil-wetted foam
Engine lubrication
Engine oil capacity
Fuel
oil grade
SAE 10W30 service class SF or SG
1.1 (1.2)
l (qts.)
Regular unleaded gasoline
type
Fuel tank capacity
l (gal.)
21 (5.5)
Fuel consumption
l (qts.)/hr.
3.9 (4.1)
Running time continuous load
wc_td000248gb.fm
5.4
hrs.
69
Threadlockers and Sealants
Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker Neuson equipment.
TYPE
( ) = Europe
Loctite 222
Hernon 420
Omnifit 1150 (50M)
COLOR USAGE
Purple Low strength, for locking threads smaller
than 6 mm (1/4”).
Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Blue
Medium strength, for locking threads
Loctite 243
Hernon 423
larger than 6 mm (1/4”).
Omnifit 1350 (100M)
Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 271/277
Red
High strength, for all threads up to 25 mm
Hernon 427
(1”).
Omnifit 1550 (220M)
Heat parts before disassembly.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 290
Green Medium to high strength, for locking
Hernon 431
preassembled threads and for sealing
Omnifit 1710 (230LL)
weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 609
Green Medium strength retaining compound for
Hernon 822
slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L)
pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 545
Brown Hydraulic sealant
Hernon 947
Temp. range: -54 to 149°C (-65 to 300°F)
Omnifit 1150 (50M)
Loctite 592
White
Pipe sealant with Teflon for moderate
Hernon 920
pressures.
Omnifit 790
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 515
Purple Form-in-place gasket for flexible joints.
Hernon 910
Fills gaps up to 1.3 mm (0.05”)
Omnifit 10
Temp. range: -54 to 149°C (-65 to 300°F)
PART NO. –
SIZE
73287 - 10 ml
29311 - .5 ml
17380 - 50 ml
29312 - .5 ml
26685 - 10 ml
73285 - 50 ml
28824 - .5 ml
25316 - 10 ml
29314 - .5 ml
79356 - 50 ml
26695 - 6 ml
73289 - 50 ml
70735 - 50 ml
Threadlockers and Sealants
Threadlockers and Sealants (continued)
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker Neuson equipment.
TYPE
( ) = Europe
COLOR USAGE
Loctite 496
Clear
Instant adhesive for bonding rubber,
Hernon 110
metal and plastics; general purpose.
Omnifit Sicomet 7000
For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Temp. range: -54 to 82°C (-65 to 180°F)
Loctite Primer T
Aerosol Fast curing primer for threadlocking,
Hernon Primer 10
Spray
retaining and sealing compounds. Must
Omnifit VC Activator
be used with stainless steel hardware.
Recommended for use with gasket
sealants.
PART NO. –
SIZE
52676 - 1oz.
2006124-6 oz.
Torque Values
Torque Values
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness)
8.8
10.9
WRENCH SIZE
12.9
Size
Nm
ft.lb.
Nm
ft.lb.
Nm
ft.lb.
Metric
Inch
Metric
Inch
M3
1.2
*11
1.6
*14
2.1
*19
5.5
7/32
2.5
–
M4
2.9
*26
4.1
*36
4.9
*43
7
9/32
3
–
M5
6.0
*53
8.5
6
10
7
8
5/16
4
–
M6
10
7
14
10
17
13
10
–
5
–
M8
25
18
35
26
41
30
13
1/2
6
–
M10
49
36
69
51
83
61
17
11/16
8
–
M12
86
63
120
88
145
107
19
3/4
10
–
M14
135
99
190
140
230
169
22
7/8
12
–
M16
210
155
295
217
355
262
24
15/16
14
–
M18
290
214
405
298
485
357
27
1-1/16
14
–
M20
410
302
580
427
690
508
30
1-1/4
17
–
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
Torque Values
Torque Values (continued)
Inch Fasteners (SAE)
Size
Nm
ft.lb.
Nm
ft.lb.
Nm
ft.lb.
Metric
Inch
Metric
Inch
No.4
0.7
*6
1.0
*14
1.4
*12
5.5
1/4
–
3/32
No.6
1.4
*12
1.9
*17
2.4
*21
8
5/16
–
7/64
No.8
2.5
*22
3.5
*31
4.7
*42
9
11/32
–
9/64
No.10
3.6
*32
5.1
*45
6.8
*60
–
3/8
–
5/32
1/4
8.1
6
12
9
16
12
–
7/16
–
3/32
5/16
18
13
26
19
33
24
13
1/2
–
1/4
3/8
31
23
45
33
58
43
–
9/16
–
5/16
7/16
50
37
71
52
94
69
16
5/8
–
3/8
1/2
77
57
109
80
142
105
19
3/4
–
3/8
9/16
111
82
156
115
214
158
–
13/16
–
–
5/8
152
112
216
159
265
195
24
15/16
–
1/2
3/4
271
200
383
282
479
353
–
1-1/8
–
5/8
1 ft.lb. = 1.357 Nm
* = in.lb.
1 inch = 25.4 mm
Wacker Neuson SE
·
Preußenstraße 41
· D-80809 München
· Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390
Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032
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